Pivoting Drill Spindle Accessory for Even Hole Sidewall Coating
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Solution Overview
Problem
Drilling holes in carbon fiber reinforced plastics (CFRPs) often results in irregular surfaces within the holes, leading to gaps between the fasteners and the material, which can cause electromagnetic energy to be shunted, increasing current density and potentially causing thermal decomposition during electromagnetic events. Rapid and even application of electrically conductive gap filling materials to these surfaces is challenging.
Innovation Solution
A drill spindle accessory that includes a fixed plate, drive shaft, pivot plate, and working shaft, where the drive shaft is rotated by a drill motor to pivot the working shaft, allowing an applicator with a diameter less than the hole to be effectively applied against the interior sidewall, ensuring even material distribution through increased effective application diameter when rotated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an applicator with diameter less than hole diameter is used to apply material, then the applicator can be inserted into the hole, but the application area is limited and coverage is insufficient
Solution Approach 1:
The applicator system transitions from a static small-diameter applicator to a dynamic system where rotation of the drive shaft causes the working shaft to pivot, dynamically increasing the effective application diameter to match the hole diameter for complete coverage
Solution Approach 2:
The system adds a rotational dimension to the applicator operation. By rotating the drive shaft, the working shaft pivots to expand the applicator's reach from a single point to a circular path that covers the entire hole interior surface
2Productivity
If manual application method is used, then equipment complexity is low, but application speed is slow and operator fatigue is high
Solution Approach 1:
The drill motor serves multiple functions: it provides both the rotational motion needed to pivot the working shaft and the driving force for material application, eliminating the need for separate actuation mechanisms and reducing overall system complexity
Solution Approach 2:
The system uses the drill motor's own rotation to automatically pivot the working shaft and expand the applicator diameter, eliminating the need for external actuators or complex control systems
3Productivity
If rapid material application is attempted, then productivity increases, but material distribution uniformity deteriorates
Solution Approach 1:
The pivot mechanism creates a circular motion path of the applicator against the hole interior surface, ensuring uniform 360-degree coverage and eliminating dead zones that would result from linear or irregular application paths
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables rapid and even application of materials to the interior sidewall of holes, reducing operator fatigue and ensuring thorough material coverage, thereby mitigating electromagnetic energy effects by filling gaps between fasteners and the CFRP structure.
Implementation Method 1
The pivot plate is pivotally coupled to the fixed plate at a pivot point offset from the longitudinal axis of the drive shaft. The working shaft is mounted to the pivot plate.
Implementation Method 2
While the applicator is inserted in the hole, the applicator is rotated with the drill motor and an effective application diameter of the applicator is increased to urge the applicator against the interior sidewall of the hole
Data Source
AI summary
A drill spindle accessory is disclosed. The drill spindle accessory includes a fixed plate, a drive shaft, a pivot plate, and a working shaft. The drive shaft is mounted to the fixed plate. The drive shaft has a longitudinal axis that extends through a center of the fixed plate. The drive shaft is configured to be rotated by a drill motor. The pivot plate is pivotally coupled to the fixed plate at a pivot point offset from the longitudinal axis of the drive shaft. The working shaft is mounted to the pivot plate. The working shaft has a longitudinal axis that extends through a center of the pivot plate.